I have just joined the community and looking forward to learn a lot in here. I own a used H16, which is equipped with a rather DIY tiller cross bar, that is an aluminum tube with racing end caps attached on each sides. The length of this crossbar from hole to hole (on the end caps) is 192 cm. The adjustable screw is extended just a few turns in order to "close" the rudders by 4-5 mm.

What is the problem:I have recently purchased a club-easy tiller cross bar, without noticing the differences in the end caps, not to say the entire tiller connection kit needed yo connect the bar to the ruder arms...

The easy-club tiller bar is 184 cm from hole to hole (on the club end caps), when the adjustable tiller cap (which slides in and out doesn't screw like the racing type) is not extended.

My first thought was to remove end caps from the old tiller crossbar and install them with riverts on the new tiller cross bar. Yet, even if I extend the adjustable screw a lot, I don't seem to make it to 192cm. (I safely reach about 188cm...).

So the question is, is there anyway to save me from returning the new crossbar, by combining bits a pieces on the club crossbar, or am I facing a deadlock situation here?

This is a rather confusing post. Not sure what an "easy club" bar is but it sounds like you have described using a newer style bar (screw adjuster) and replacing it with the older style bar (slide adjuster). As such, the bar you want to use is too short?? Is that accurate? Or do you have only one bar and you are wanting to modify it?

The older style crossbar is typically used with the bent rudder arms. I believe the newer ones use straight rudder arms. Are your rudder arms straight or bent? If they are bent maybe you just have them on the wrong side of the boat...reverse them so that they point inboard. Or, as happened on one of my boats, someone replaced the crossbar with one from a Hobie 14.

Making matters worse, some older boats had slide adjusters on one end and others on both ends so trying to determine the "correct" length of the bar is a challenge especially if it was modified (DIY) before you owned the boat.